What s new in EZCAM Version 18

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1 CAD/CAM w w w. e z c a m. com What s new in EZCAM Version 18 MILL: New Curve Machining Wizard A new Curve Machining Wizard accessible from the Machining menu automates the machining of common part features by applying multiple predefined worksteps to an active curve. Users can define their own feature categories, for example Holes, Pockets, or Profiles, and corresponding machining methods to machine specific configurations. By using the Curve Machining Wizard, complex multi step process can be created with just a few clicks of the mouse. The Curve Machining Wizard allows extensive customization. User categories can be added to the Category pick list by defining new folders in the predefined sub directory called C:\EZCAMW\EZCAM18\WorkstepComboMetric. Machining methods are defined by creating EZ-CAM.3dp files containing the worksteps required to machine specific features, then storing them with a descriptive name in the applicable Category folder. For example a.3dp file could be defined to spot drill, drill, and tap an M10x1.5 hole using three worksteps, and then be saved as Tapped_Hole_M10x1.5.3dp in the Hole category folder. In order to apply the hole making method in the future, the user simply defines the hole pattern Curve then uses the Curve Machining Wizard to select the Hole Category and apply the Tapped_Hole_M10x1.5 Method. The spot drill, drill, and tap worksteps are then automatically added to the job with the required machining parameters preset.

2 When Machining Method worksteps are retrieved, the Curve Machining Wizard dialog box displays the worksteps in a table, which allows the primary parameters to be changed as needed. Common settings such as Z Surface, Rapid, and Clear can be set for all worksteps by entering the required values into the shared Z Data fields and choosing the Update Workstep button. The shared Depth parameter can also be specified, and will be used to update the depth of any workstep that was stored with its Depth set to zero. If a workstep Depth parameter remains set to zero, the curve Z level is used for the absolute depth position. Machining method worksteps can also be stored with the Depth specified as an incremental adjustment value by preceding the value with a + or - sign. Worksteps with signed values will set the Z depth position to the curve Z level, plus or minus the specified amount. User Categories (Sub-Foldes) Features in selected category The new Curve Machining Wizard saves time by eliminating the numerous steps that would otherwise be required to manually define a sequence of machining worksteps. Job accuracy and repeatability are ensured, by applying standard shop practices using proven parameters and settings. MILL 3D Machining Wizard: Sequential Re-roughing The 3D Machining Wizard Re- Roughing method now allows previous Re-Roughing worksteps to be used as input for subsequent roughing of remaining material. This feature allows a more optimal re-roughing strategy to be employed, where progressively smaller tools are used in order to maintain the highest possible rigidity during each re-roughing phase. Standard Roughing 1 st Re-Roughing 2 nd Re-Roughing

3 MILL 3D Machining Wizard: Equidistant Finishing Flat Area Machining The 3D Machining Wizard Equidistant Finishing method now allows the machining to be restricted to only flat areas, by specifying a Surface Angle of 0. This feature can be used to remove remaining stock from island tops and shelves after roughing using the new Ignore Flats option. Solid model surfaces Equidistant flat area machining MILL 3D Machining Wizard: New 3D Pencil Milling Method The Wizard now contains a new Pencil Milling method, which generates toolpath to machine all concave surface intersections where the specified tool makes dual contact. This capability is useful for removing material remaining in corners and along fillets in both finish and semi-finishing applications. Multiple Pencil Milling worksteps using progressively smaller tools can be used to trace along part features, gradually removing remaining material.

4 MILL 3D Machining Wizard: 3D Roughing Face Stock The 3D Machining Wizard Parallel Roughing method now supports a Face Milling option, which when enabled treats the selected model surfaces as stock to be machined away. The selected surfaces are sliced at each depth increment and the resulting profiles are cut using a linear toolpath pattern with the boundary offset toward the outside by the tool radius. This method can be used to remove irregular stock protruding above a face, by creating a model that represents the stock, then selecting it for machining instead of part model surfaces. Green = Stock to be removed Toolpath detecting increase of model size at each Z-Step MILL 3D Machining Wizard: 3D Roughing Ignore Flats The 3D Machining Wizard Pocket and Parallel Roughing methods now support a new Ignore Flats option, which when enabled allows the roughing routine to rough the entire model using the specified depth increment, without adding additional depth levels for horizontal faces. This feature reduces machining time by eliminating the additional cut levels that would otherwise compromise the cut depth increment. When this option is used, the remaining horizontal face stock can be removed in a subsequent workstep using the new flat-area machining feature. Ignore Flats: Disabled Ignore Flats: Enabled

5 MILL 3D Machining Wizard: Equidistant Finishing Scallop Height Step Over The 3D Machining Wizard Equidistant Finishing method now contains a new Scallop Height step over option, available when ball and bull endmills are used. When Scallop Height is enabled, the input Step Over value is interpreted as a maximum cusp height, and spacing between 3D offsets is automatically calculated in order to ensure the specified cusp value is not exceeded. This new option saves time by ensuring the desired surface finish smoothness is achieved without guess work, eliminating the possibility of generating more or fewer cuts than are necessary. Scallop Height Stepover: Disabled Scallop Height Stepover: Enabled MILL: Open Pocket Machining The Curve Motion Record now includes a new Open Edge attribute, which allows closed curve boundaries to include segments marked as open. When curves containing open edges are used by Pocketing or Zigzag cycles, the open edge segments are offset outward, allowing the boundary to be treated as an open pocket. The default start position of the Pocket cycle pattern is oriented along the longest Open Edge, thereby allowing the tool to descend clear of stock when machining from outside in. This feature allows boundary curves to be used directly from the model, without the need to manually create additional offset geometry and modify the curve.

6 MILL: Automatic Insertion of Contour Tabs The Contour cycle has been enhanced to provide options to automatically insert rapid breaks along the curve profile. The rapid breaks are defined by specifying a number of tabs and tab width in the workstep Cycle Data dialog box. The tab positions are distributed along the curve profile, splitting the first tab span across the start/end position of the curve. This feature is useful when cutting flat parts from sheet stock, allowing the individual parts to remain connected to the sheet. MILL: HSM Smooth Roughing Toolpath A new Smooth HSM option, available in the Constant Z, Pocket and Zigzag cycles, generates completely smooth roughing toolpath. Offset Pocket patterns are created with inside corner fillets and smooth S-link connections to the adjacent offset passes. Bi-directional Zigzag patterns connect each pass using filleted connections. The corner radii and filleted connections use a radius equal to 40% of the Step Over distance. These new smooth patterns allow higher feedrates to be used while minimizing shock to the machine and cutting tool. Pocketing / Zig-Zag HSM disabled Pocketing / Zig-Zag HSM enabled

7 MILL / TURN: Curve Boolean Operations New Curve Boolean Operations allow the active curve to be modified by referencing a second curve, and performing the specified Boolean operation. Union, Intersect, and Subtract operations are supported. This new capability allows complex curve boundaries or paths to be formed directly from slice or boundary curves, without the need to manually create and edit wire frame geometry. Original Curves, Left=Crv1 / Right=Crv2 (active) Boolean Operation = Union Boolean Operation = Intersect Boolean Operation = Substract TURN: Create Curve from Spun Solid Model The EZ-Turn Automation menu contains a new method to automatically create a turning profile by spinning the solid model about the Z Axis. This feature allows a composite profile diameter curve to be generated from a model containing non-symmetrical features. It saves time by eliminating the need to manually orient and slice the model at multiple positions, and then editing the resulting slice curves into a single turning profile. Imported 3D model in shaded isometric view 2D Curve created from rotated model

8 MILL: Nested Curve Loop Reordering New Inner to Outer and Outer to Inner Curve ordering commands, available in the Curve Direction menu, automatically sort nested curve loops, ordering them from the inside out, or outside in. Inner to Outer orients the outermost loop direction to clockwise, and Outer to Inner to counter clockwise. The directions of subsequent nested inner loops are alternated. The Outer to Inner method is a convenient method to establish a climb cut direction for the pocket and islands scenarios. The inner to Outer method is useful for cutting parts from sheet stock, allowing a climb cut convention to be established for inner voids, and around outer part profiles. If the connected profiles aren t nested at all, then Inner to Outer will reverse all subprofiles to clockwise direction, Outer to Inner to counter-clockwise direction. Original curve with chained subprofiles Step1: Reverse - Inner to Outer applied Step2: Reverse Outer to Inner applied MILL: Canned Drilling Cycle G98/G99 Return Level The Post Processor is now capable of supporting Fanuc style G98 return to Initial plane, or G99 return to Retract plane behaviors. The SAX Basic format language provides new conditional logic statements that can be used to output the required G98/G99 codes based on the Rapid or Linear link types of the curve used by drilling work step.

9 MILL: Calculate Speeds/Feeds Max RPM The Work Step Data feeds and speeds Calculate function now limits the maximum RPM to the value specified in the General Information section of the active post processor. This feature prevents an RPM value from being output that exceeds the target machine tool limit. MILL: Retract To Clear This new option, located in the Z Data section of the machining dialogs, can be used when contouring open profiles with multiple Z steps. Usually, at the end of each pass, the system retracts to Z rapid plane before moving back to the original plunge location. As these Z rapid moves can be quite time consuming, the new option retracts to clearance level above previous steps Z plane before moving back in X and Y. To Clear = Disabled To Clear = Enabled TURN: New Worksheet Document A new Create Worksheet Document command in the Automation menu can be used to create a setup sheet for the current job containing a tool and work step list. The work step data is exported to Microsoft Word and a macro is used to create the document and format the data into tables. This feature allows shop floor documentation to be generated automatically with one simple command. EXPRESS MILL / TURN: Workstep ID Input (EZ-CAM Express) The EZ-CAM Express products now allow a descriptive alphanumeric ID to be assigned to each workstep. This feature makes it easy to identify which worksteps perform a specific operation. All Modules: Updated CAD Data Translation - The CAD data translator has been updated to support the latest file formats, and improve translation quality. Solidworks 2010.sldprt and Autocad 2010.dwg files can now be imported. The ACIS SAT translation has also been updated and improved. These changes ensure complete compatibility with the latest versions of popular CAD systems.